Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
  • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
  • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
  • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
  • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
  • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
  • F01N3/30—Arrangements for supply of additional air
  • F01N3/306—Preheating additional air
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
  • B01J19/24—Stationary reactors without moving elements inside
  • B01J19/248—Reactors comprising multiple separated flow channels
  • B01J19/2485—Monolithic reactors
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
  • B01J19/24—Stationary reactors without moving elements inside
  • B01J19/248—Reactors comprising multiple separated flow channels
  • B01J19/2495—Net-type reactors
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
  • B01J19/26—Nozzle-type reactors, i.e. the distribution of the initial reactants within the reactor is effected by their introduction or injection through nozzles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
  • B01J8/02—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds
  • B01J8/04—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds
  • B01J8/0403—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds the fluid flow within the beds being predominantly horizontal
  • B01J8/0423—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds the fluid flow within the beds being predominantly horizontal through two or more otherwise shaped beds
  • B01J8/0438—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds the fluid flow within the beds being predominantly horizontal through two or more otherwise shaped beds the beds being placed next to each other
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
  • B01J8/02—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds
  • B01J8/04—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds
  • B01J8/0496—Heating or cooling the reactor
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
  • C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen; Reversible storage of hydrogen
  • C01B3/02—Production of hydrogen; Production of gaseous mixtures containing hydrogen
  • C01B3/32—Production of hydrogen; Production of gaseous mixtures containing hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide or air
  • C01B3/34—Production of hydrogen; Production of gaseous mixtures containing hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide or air by reaction of hydrocarbons with gasifying agents
  • C01B3/38—Production of hydrogen; Production of gaseous mixtures containing hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide or air by reaction of hydrocarbons with gasifying agents using catalysts
  • C01B3/386—Catalytic partial combustion
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
  • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
  • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
  • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
  • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
  • F01N3/023—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles
  • F01N3/025—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles using fuel burner or by adding fuel to exhaust
  • F01N3/0253—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles using fuel burner or by adding fuel to exhaust adding fuel to exhaust gases
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
  • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
  • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
  • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
  • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
  • F01N3/023—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles
  • F01N3/025—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles using fuel burner or by adding fuel to exhaust
  • F01N3/0253—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles using fuel burner or by adding fuel to exhaust adding fuel to exhaust gases
  • F01N3/0256—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles using fuel burner or by adding fuel to exhaust adding fuel to exhaust gases the fuel being ignited by electrical means
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
  • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
  • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
  • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
  • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
  • F01N3/0828—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents characterised by the absorbed or adsorbed substances
  • F01N3/0842—Nitrogen oxides
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
  • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
  • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
  • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
  • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
  • F01N3/0871—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents using means for controlling, e.g. purging, the absorbents or adsorbents
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
  • B01J2208/00008—Controlling the process
  • B01J2208/00017—Controlling the temperature
  • B01J2208/00389—Controlling the temperature using electric heating or cooling elements
  • B01J2208/00415—Controlling the temperature using electric heating or cooling elements electric resistance heaters
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
  • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
  • C01B2203/02—Processes for making hydrogen or synthesis gas
  • C01B2203/0205—Processes for making hydrogen or synthesis gas containing a reforming step
  • C01B2203/0227—Processes for making hydrogen or synthesis gas containing a reforming step containing a catalytic reforming step
  • C01B2203/0244—Processes for making hydrogen or synthesis gas containing a reforming step containing a catalytic reforming step the reforming step being an autothermal reforming step, e.g. secondary reforming processes
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
  • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
  • C01B2203/02—Processes for making hydrogen or synthesis gas
  • C01B2203/025—Processes for making hydrogen or synthesis gas containing a partial oxidation step
  • C01B2203/0255—Processes for making hydrogen or synthesis gas containing a partial oxidation step containing a non-catalytic partial oxidation step
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
  • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
  • C01B2203/02—Processes for making hydrogen or synthesis gas
  • C01B2203/025—Processes for making hydrogen or synthesis gas containing a partial oxidation step
  • C01B2203/0261—Processes for making hydrogen or synthesis gas containing a partial oxidation step containing a catalytic partial oxidation step [CPO]
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
  • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
  • C01B2203/12—Feeding the process for making hydrogen or synthesis gas
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
  • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
  • C01B2203/12—Feeding the process for making hydrogen or synthesis gas
  • C01B2203/1205—Composition of the feed
  • C01B2203/1211—Organic compounds or organic mixtures used in the process for making hydrogen or synthesis gas
  • C01B2203/1235—Hydrocarbons
  • C01B2203/1247—Higher hydrocarbons
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
  • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
  • C01B2203/16—Controlling the process
  • C01B2203/169—Controlling the feed
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
  • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
  • F01N2240/00—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being
  • F01N2240/20—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being a flow director or deflector
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
  • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
  • F01N2240/00—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being
  • F01N2240/30—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being a fuel reformer
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
  • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
  • F01N2570/00—Exhaust treating apparatus eliminating, absorbing or adsorbing specific elements or compounds
  • F01N2570/14—Nitrogen oxides
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
  • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
  • F01N2610/00—Adding substances to exhaust gases
  • F01N2610/10—Adding substances to exhaust gases the substance being heated, e.g. by heating tank or supply line of the added substance
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
  • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
  • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
  • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
  • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
  • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
  • F01N3/36—Arrangements for supply of additional fuel
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
  • Y02A50/00—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE in human health protection, e.g. against extreme weather
  • Y02A50/20—Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters

Definitions

• This invention relates to reforming liquid hydrocarbon fuels without vaporizing the fuel by means of direct injection of the liquid hydrocarbon fuel through an atomizing nozzle, into either hot engine exhaust or preheated humidified air, upstream of a reformer such as a catalytic partial oxidizer (CPO) or a non-catalytic, homogenous partial oxidizer (POX), or autofhermal reformer (ATR).
• a reformer such as a catalytic partial oxidizer (CPO) or a non-catalytic, homogenous partial oxidizer (POX), or autofhermal reformer (ATR).
• the exhaust clean-up processing 16 receives syngas, which is a reformate including hydrogen, some CO and some CO , as is known, over a conduit 17 from a reformer which in this embodiment is a CPO 18. Examples of the exhaust clean-up processing may be found in U.S. patent applications having serial numbers and filed as follows: 10/243,105, September 13, 2002; 10/309,712, December 4, 2002; and 10/658,494, September 8, 2003.
• the manner of using the syngas which is produced in accordance with the invention is not relevant to the invention; instead, the invention relates to the manner of producing the syngas for emission reduction of internal combustion engines.
• fuel in the line 10 is vaporized in a vaporizer 65 which is raised to a sufficiently high temperature by a heater 66 which surrounds the vaporizer.
• the vaporized fuel in a conduit 68 has preheated air mixed with it from a conduit 69, both of which are provided to a mixer 70 at the entrance to the CPO 18 (or other reformer).
• An alternative approach known to the prior art is illustrated in Fig. 2. Therein, the hot engine exhaust may be fed directly to the vaporizer 65, and the fuel injected into the vaporizer. This requires less energy from the heater 66.
• Vaporizing liquid fuels can cause coke build-up within the vaporizer, and contributes coke particulates into the flow into the reformer, which causes deactivation of the catalyst.
• the vaporizer adds to the cost, weight and complexity of the system.
• Disclosure of Invention Objects of the invention include: eliminating the need for a separate vaporizer for liquid hydrocarbon fuel feed stock being fed to a reformer; eliminating the problems due to coke formation in the reformation of liquid hydrocarbon fuels; eliminating catalyst deactivation due to coke; improved generation of syngas for use in regenerating NOx and particulate adsorbers in internal combustion engine systems; improved generation of hydrogen from liquid hydrocarbon fuels; and reduced cost of liquid hydrocarbon fuel reformers.
• liquid hydrocarbon fuel is injected directly into the hot engine exhaust of a diesel engine, or preheated humidified air, at the inlet to a hydrocarbon fuel reformer, such as a CPO, a POX or an ATR.
• a high degree of mixing of the liquid hydrocarbon fuel with the oxygen contained in either the engine exhaust or in the humidified air is accomplished simultaneously with the gas assisted atomization and resultant vaporization of the liquid hydrocarbon fuel.
• a mixer such as inert ceramic foam, is disposed between an atomizing nozzle and the reformer.
• the radiation heat causes the mixer to achieve high temperature, which may be on the order of between 700°C (1292°F) and 1200°C (2192°F).
• the mix of heated oxygen and vaporized fuel causes an initial partial reformation of the hydrocarbon fuel into its constituents prior to reaching the CPO reformer itself. This prereformation has been referred to, and is identified herein as a "cold flame" reformation process.
• Use of the cold flame process not only provides a more complete reformation in the reformer, but also reduces the peak temperature of the CPO which thus reduces the long term degradation of the CPO catalyst.
• Use of the invention indicates that the yield of hydrogen and carbon monoxide after several hundred hours is within about one or two percent of the initial yield. This shows that deterioration of the catalyst is minimal when utilizing the present invention.
• atomizing fuel and use of a glow plug igniter allows immediate light off of very rich air/fuel mixtures (air/fuel about 0.014), even though the lower limit of air/fuel ratios for flammability is generally considered to be 0.2, and light off of the CPO reformer at about 175°C (350°F), which is a much lower temperature than the 350°C (660°F) nominally required for light off without the invention.
• a hydrocarbon fuel igniter comprises a catalyst coated heater wire.
• Fig. 1 is a simplified schematic diagram of an engine system of the prior art employing a fuel vaporizer to create syngas for use in cleaning the exhaust of the engine.
• Fig. 2 is a simplified schematic diagram of an alternative prior art system employing a vaporizer.
• Fig. 3 is a simplified schematic diagram of an engine system utilizing the present invention to create syngas for use in cleaning the exhaust of the engine.
• Fig. 4 is a partial, simplified schematic diagram of the configuration of Fig. 1 but with a gas-assist nozzle using hot engine exhaust as the assisting gas.
• Fig. 5 is a partial, simplified schematic diagram of the configuration of Fig. 1 but with a gas-assist nozzle using turbocharger air as the assisting gas.
• Fig. 1 is a simplified schematic diagram of an engine system of the prior art employing a fuel vaporizer to create syngas for use in cleaning the exhaust of the engine.
• Fig. 3 is a simplified schematic diagram of an engine system utilizing the present invention to create syn
• FIG. 6 is a simplified schematic diagram of a system for generating syngas from unvaporized fuel and humidified air.
• Fig. 7 is a partial schematic diagram of a steam-assisted nozzle.
• Fig. 8 is a simplified schematic diagram of another system for generating syngas from unvaporized fuel and humidified air with an air-water bubbler.
• Fig. 9 is a simplified schematic diagram of a system generating syngas from fuel and exhaust through a gas assist atomizing fuel nozzle, ignited at the inlet to the clean-up processing.
• Fig. 10 is a fragmentary, simplified perspective view of an alternative igniter in accordance with the invention.
• the CPO 18 may have a high temperature structural support, such as an inert ceramic foam 19, separated from the CPO entrance by a gap 20, which will provide partial conversion of the hydrocarbon fuel as it reaches an elevated temperature.
• a high temperature structural support such as an inert ceramic foam 19
• fuel is provided by an atomizing nozzle 22; the fuel is received through a pulse-modulated valve 23 from the fuel line 10.
• the mixing chamber 21 also receives engine exhaust through a valve 25 from the engine exhaust pipe 12. If desired for rapid startup, a glow plug igniter 26 is utilized to initiate ignition of a low air/fuel ratio mixture to quickly heat the CPO 18 to operating temperature.
• the valves 23, 25, the igniter 26, and the exhaust treatment 16 are all responsive to a controller 28.
• the fuel is at ambient temperature, and it is not vaporized prior to injection into the mixing chamber 21, but is simply atomized as it is injected through the atomizing nozzle 22 into the mix within the mixing chamber 21 where it vaporizes.
• the engine exhaust passing through the valve 25 supplies oxygen and moisture for the catalytic reformation process in the CPO 18.
• utilization of the inert ceramic foam 19 begins the reformation process by converting some of the fuel into some of its constituents.
• the fuel also consumes some oxygen which helps to reduce the peak temperature of the CPO, so that the CPO catalyst will last longer and the process will be more complete. Referring to Fig.
• the atomizing nozzle 22a may comprise a gas-assist atomizing nozzle, which may for instance, comprise an air-assist nozzle produced by Orbital, similar to those used for atomizing fuel oil in residential furnaces.
• the assist gas is exhaust which passes through a valve 30 under control of the controller 28.
• the embodiment of Fig. 2 also illustrates that one aspect of the invention, the atomizing nozzle 22 which eliminates the need to use a vaporizer for the fuel, may be used in a CPO 18 which does not have inert ceramic foam 19 near the inlet thereof.
• the gas for the gas assist atomizing nozzle may be provided by a vehicle's turbocharger 33, which provides a small amount of air through a valve 34 under control of the controller 28.
• the assist gas for a gas assist nozzle may be humidified air, engine exhaust or steam.
• other atomizing nozzles may be used, as desired, to suit any implementation of the present invention.
• the invention as described, utilizing an atomizing fuel nozzle to eliminate the need for a vaporizer for the liquid hydrocarbon fuel may thus find significant application in cleaning up internal combustion engine exhaust, such as in particulate removal devices and NOx removal devices.
• the invention may also be used other than in vehicles with internal combustion engines. Referring to Fig.
• the atomizing nozzle 22 receives fuel through a valve 37 from a source of fuel 38.
• the fuel may be gasoline, diesel fuel, or any other liquid hydrocarbon fuel, such as kerosene, JP-8 and jet fuel.
• the mixing region 21 is provided humidified air in a conduit 39 through a valve 40 from an ejector 41 that ingests water over a line 42 from a tank of water 43. Hot air is provided on a line 47 by a heat exchanger 48 which receives air over a line 49 from an air turbocharger or an air pump 50.
• the output in a conduit 55 is reformate, sometimes referred to as "syngas", which includes hydrogen, CO and some CO 2 , along with nitrogen, steam and unconverted hydrocarbons, all as is known to the art.
• the igniter 26 is utilized at the start of the process to cause ignition of unpreheated air/fuel mixture, with air/fuel ratios as low as 0.014, well below the generally accepted flammability limit.
• the mixture rapidly rises to about 175°C (350°F) at which point the catalytic process begins, bringing the CPO to its peak temperature of on the order of between 1050°C and 1250°C (1922°F and 2282°F), after which, the igniter 26 may be disenergized and the process is self-sustaining from the heat of the CPO.
• steam may be used as the assist gas if a gas-assisted atomizing nozzle is used, as illustrated by the steam generator 57 in Fig. 7.
• the reformate provided through the heat exchanger 48 in the conduit 55 may either be utilized as is, or it may undergo further processing, such as water/gas shift reactions, to convert CO to provide more hydrogen, and a preferential CO oxidizer, to reduce CO.
• Fig. 8 illustrates the invention utilized with an engine wherein air from the turbocharger 33 is humidified in a bubbler/water tank combination 60, as described in the aforementioned application Serial No. 10/243,105.
• Fig. 9 illustrates that the mixing region 21 can effectively become the POX, the igniter 26 igniting the fuel and exhaust mixture passing through the gas assist atomizing nozzle, which burns additional exhaust components in the mixing chamber 21.
• This hot syngas mixture then flows directly into the exhaust treatment, which may comprise a catalyzed particulate filter 62 and a catalyzed NOx adsorber 63, as is known in the art.
• the use of the gas assist atomizing nozzle permits applying the generated syngas directly into the exhaust as shown.
• the atomized liquid fuel within the mixing chamber 21, particularly if it is gasoline, is extremely explosive. Therefore, the igniter should not be a spark plug for safety reasons. Instead of using a glow plug, however, the igniter may comprise, as shown in Fig. 10, a heater wire, which may be formed in the shape of a helix 66, wash-coated with a CPO catalyst, and placed in front of the ceramic foam 19.
• This igniter may be used in a POX or to assist light-off of a CPO or an ATR. In the invention, only sufficient oxygen should be used to reach the CPO temperature, any additional oxygen merely reducing the hydrogen yield. Without use of a catalyst, such as a homogeneous POX, the glow plug must be at a much higher temperature, and must be energized continuously.

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• 2004
  • 2004-06-14 US US10/867,433 patent/US20050274107A1/en not_active Abandoned
• 2005
  • 2005-06-09 WO PCT/US2005/020427 patent/WO2005124917A2/en not_active Ceased
  • 2005-06-09 EP EP05760329A patent/EP1784889A2/de not_active Withdrawn
  • 2005-06-09 JP JP2007516568A patent/JP2008502847A/ja not_active Abandoned

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